Container having improved strength

ABSTRACT

A container for consumer articles is at least partially formed from a laminar blank having an inner surface and an outer surface, and a thickness (T) of from about 100 micrometers to about 350 micrometers. The laminar blank defines a portion of the container that comprises a first planar wall and a second planar wall connected to one another by a first edge portion. The inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, each of which is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion. The laminar blank is folded about the one or more ablated lines such that, for each ablated line, the angle (a) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of:

The present invention relates to a container for consumer goods and to a blank for forming such container, which find particular application for holding elongate consumer goods, such as smoking articles (for example, cigarettes). The present invention also relates to a method for forming such containers.

Smoking articles such as cigarettes and cigars are usually provided in soft-pack packs or hard-pack packs, such as flip-top boxes or hinge-lid boxes. These typically have a box part having a box front wall, a box rear wall, box side walls and a box base. They also usually have a lid part with a lid front wall, a lid rear wall, lid side walls and a lid top side. The lid part is typically hinged to the box part along a hinge line extending across a back wall of the container. The hinge line is usually provided as a pre-folded line, a crease line or a score line.

Hard-pack containers, or at least portions thereof, are typically obtained from a laminar blank comprising a plurality of panels. In order to assemble a container, one such blank is folded so that panels of the blank can form walls of the containers.

For hard-pack packs, it is known to round off or chamfer certain edges of the box and lid to give the container a distinctive appearance. This has typically been achieved in the past by providing creasing lines or scoring lines in the blank at the areas forming the edges of the container. These lines allow the blank to be folded in such a way that the edge does not simply bend along a single line, but instead either progressively bends between two adjacent walls (in the case of a round edge), or bends at two or more discrete locations between adjacent walls (in the case of a bevelled edge).

However, such scoring or creasing lines can add complexity to the manufacturing process. Furthermore, in some cases, the visual and tactile perception of the container may be impacted, in that the outer surface is not entirely smooth and can include ridges or ripples from where the creasing has occurred.

It would therefore be desirable to provide a container for consumer goods having one or more curved edges that has an improved look. It would also be desirable to provide to provide a container for consumer goods having an edge portion that has improved strength and which is easier to produce. Further, it would be desirable to provide a blank for manufacturing a container for consumer goods that make the production and assembly process easier and more flexible.

According to a first aspect of the present invention, there is provided a container for consumer articles, the container being at least partially formed from a laminar blank having a thickness (T) and an inner surface and an outer surface, the laminar blank defining a portion of the container that comprises: a first planar wall; and a second planar wall connected to the first planar wall by a first edge portion, wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, wherein the laminar blank is folded about the one or more ablated lines of the first edge portion such that, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

According to a second aspect of the present invention, there is provided laminar blank for forming a container for consumer articles, the laminar blank having a thickness (T) and an inner surface and an outer surface, the blank comprising: a first wall panel for forming a first planar wall of the container; and a second wall panel for forming a second planar wall of the container, the second wall panel being connected to the first wall panel by a first edge portion; and wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, and wherein the laminar blank is configured to be folded about the one or more ablated lines of the first edge portion such that when folded, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

According to a third aspect of the present invention, there is provided a method of forming a container for consumer articles, the container being at least partially formed from a blank having a thickness (T), the method comprising: providing a laminar blank having a thickness (T), the blank comprising: a first wall panel for forming a first planar wall of the container; and a second wall panel for forming a second planar wall of the container, the second wall panel being connected to the first wall panel by a first edge portion; wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion; and folding the first wall panel of the laminar blank relative to the second wall panel, such that, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

It shall be appreciated that any features described with reference to one aspect of the present invention are equally applicable to any other aspect of the invention.

In contrast to known containers that use mechanical creasing lines for defining an edge portion of the container, the present invention involves the removal of material from specific locations within the portion of the blank that defines a first edge portion of the container. The provision of ablation areas including ablated (for example, by laser ablation) lines to form the first edge portion of the container advantageously reduces the force required for folding the blank about the first edge portion.

However, this also results in the container being more vulnerable to local deformation about the first edge portion, since there is less material to resist an external force. In order to solve this problem, the present inventors have identified that material should be removed from the blank in accordance with certain criteria. In particular the present inventors have identified that material should be removed from the blank, such that, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

This allows the blank to be folded at any one ablation groove in such a way that the sides of an ablation groove come into contact with one another and thereby provide additional strength at said edge portion. This results in a pack that is more robust and less likely to deform when subjected to an external force. Accordingly, the present inventors have surprisingly found that it is actually possible to remove material from the inner surface of the blank, in such a way that the blank is easier to fold, whilst also being more robust and less likely to deform when subjected to an external force.

The container can be conveniently formed from a single blank by a conventional packing machine. In addition, because the outer surface of the blank is unaffected by the ablation process, the resulting outer surface of the container does not exhibit localised ridges or ripples at the ablation line location (as would be the case with mechanical creasing lines).

The blank of the present invention may advantageously be manufactured by precisely removing material from the first edge portion with a linear ablation tool (for example, a laser or a blade). A laser is a particularly preferred ablation tool, as it is non-invasive and can be digitally programmed for improved flexibility of design. In particular, use of a laser as the ablation tool can allow for a wide variety of ablation profiles and configurations, with minimal adjustment of the laser tool being needed. Repeated passages of the ablation tool over a given portion of the blank results in the removal of a greater percentage of material, that is in a reduced residual thickness. Thus, the manufacturing process can be simplified. Laser ablation may be obtained using any suitable equipment, preferably a 1000 Watt CO2 laser as commercially available from DIAMOND, e.g. the E-1000. Ablation may be obtained in machine direction of the laminar blank or in cross direction.

Containers made of the laminar blank of the present invention can be obtained without a pre-bending step, which is usually required with traditional methods for obtaining round corners like embossing.

The term “edge portion” is used herein to refer to the portion of the blank defining an edge between two adjacent walls of the container. The first edge portion being the portion of the blank defining an edge between the first planar wall and the second planar wall.

In some embodiments, the first edge portion may have a relatively small width, and have a square shape as viewed in cross-section. In such embodiments, the inner surface of the first edge portion may only contain one ablated line.

Alternatively, the first edge portion may have a larger width, and have a non-square shape as viewed in cross-section. This may for example refer to a “curved edge portion”, that is an edge portion of the container having an arc-like shape as viewed in cross-section. By the term “arc-like” reference is made to any non-straight line, including circular arc, parabolic arc, hyperbolic arc, elliptical arc, etc. Preferably, however, the first edge portion is a “bevelled edge portion”, that is an edge portion of the container that has, as viewed in cross-section, one or more substantially straight shapes forming an angle between 0 and 90 degrees with the adjacent walls of the container. The bevelled edge portion may be defined by only two ablation lines, such that a single facet extends between the first planar wall and the second planar wall. Alternatively, the ablation area may comprise at least three ablated lines at any given longitudinal position. For such embodiments, the bevelled edge portion will comprise two or more facets extending between the first planar wall and the second planar wall. The facets may have any suitable shape, but preferably are substantially rectangular.

The term “inner surface” is used throughout the specification to refer to the side of a portion of the blank that, once the container is assembled, faces towards the interior of the container, for example towards the consumer goods, when the container is closed. Thus, the inner surface is not directly visible for the consumer when the container is closed. The term “outer surface” is used throughout the specification to refer to the side of a portion of the blank that, once the container is assembled, faces towards the exterior of the container.

The term “ablated line” is used herein to refer to a line along the inner surface of the edge portion from which material has been ablated (for example, removed by means of a laser beam or a blade). Accordingly, the residual thickness of an ablated line is less than the thickness (T) of the laminar blank. The ablated line is preferably provided as a groove within the blank. This may be formed with a linear ablation tool, such as a laser or a blade.

The “thickness” (T) of the blank is the thickness of the blank after it has been manufactured, but before any ablation lines or creasing lines have been formed in the blank. That is, the thickness (T) of the blank is the thickness in any region of the blank not containing an ablated line or a crease line.

The term “residual thickness” is used herein to refer to the minimum distance measured between two opposite surfaces of the laminar blank or of a wall of the container formed from the blank. In practice, the distance at a given location is measured along a direction locally perpendicular to the opposite surfaces. The residual thickness of the ablated line may vary across a width of the ablated line, (e.g. V-shaped, U-shaped grooves).

The term “minimum residual thickness” is used herein to refer to the smallest value of “residual thickness” measured in an ablated line.

As used herein, the terms “front”, “back”, “upper”, “lower”, “top”, “bottom” and “side”, refer to the relative positions of portions of containers according to the invention and components thereof when the container is in an upright position with the access opening at the top of the container. In particular, where the container is a hinged lid container, this refers to the container being in an upright position with the lid in the closed position and the hinge line at the back of the container. When describing containers according to the present invention, these terms are used irrespective of the orientation of the container being described.

The term “spring-back force” is a known term of art for referring to a particular property of a laminar blank. It is sometimes referred to as ‘the crease recovery’ and means the force (N) required to hold a scored sample that is folded at 90 degrees for a 15-second period. The measurement is made at the end of the 15-second period. The spring-back force of a portion of a laminar blank can be measured using a known PIRA Crease and Board Stiffness Tester (commercially available for example from Messmer and Buchel, UK). As is known in the art, to measure the spring-back force of an edge portion of a container, a sample of the portion to be tested should first be removed from the laminar blank. For the purposes of the present invention the spring-back force of a pack is assessed using a sample measuring 38±1 millimetres by 38±0.5 millimetres, with the first edge portion being positioned 21±0.5 millimetres from one side of the blank. The blank should be conditioned at 22 degrees Celsius and 60 percent relative humidity for at least 24 hours prior to testing.

Preferably, the angle (α) is at least:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

Preferably, each of the one or more ablated lines is formed as a substantially V-shaped groove within the laminar blank. That is, preferably each of the one or more ablated lines is formed has a substantially V-shaped cross-sectional profile in the laminar blank, when the laminar blank is in an unfolded condition. The cross-sectional profile of the ablation lines can be determined using an optical profile as generated by the 2D Non-Contact Surface Metrology, such as the MicroSpy® Profile (commercially available from Fries Research & Technology GmbH, Bergisch Gladbach, Germany).

Preferably, each of the one or more ablated lines has a minimum residual thickness (RT) of less about 40 percent of the thickness (T) of the laminar blank. Preferably, each of the one or more ablated lines has a minimum residual thickness (RT) of at least about 20 percent of the thickness (T) of the laminar blank.

The residual thickness of each ablated line can be determined using an Optical Profilometer for 2D and 3D Non-Contact Surface Metrology, such as the MicroSpy® Profile (commercially available from Fries Research & Technology GmbH, Bergisch Gladbach, Germany). Preferably, several points of minimum residual thickness are measured over the length of an ablated line whereas the points of measurement are evenly spread over the length of one ablated line and the arithmetic mean is calculated. Even more preferably, to obtain the “minimum residual thickness” according to the present invention, five measurements, evenly spread over the length of an ablated line, are performed and then the arithmetic medium is calculated.

Even more preferably, to obtain the “minimum residual thickness” according to the present invention, five measurements, evenly spread over the length of an ablated line, are performed and then the arithmetic medium is calculated.

For example, if the length of the ablated line is 80 millimetres, the residual thickness is measured at both ends of the ablated line and at three further points distanced 20 millimetres, forty millimetres and sixty millimetres respectively from one end of the ablated line, preferably from the lower end of the ablated line.

The term “gap” is used herein to refer to the distance between the low points of two adjacent ablated lines.

Preferably, several points of gap are measured over the length of a pair of parallel ablated lines, whereas the points of measurement are evenly spread over the length of the parallel portions of the ablated lines and the arithmetic mean is calculated.

Even more preferably, to obtain the “gap” according to the present invention, five measurements, evenly spread over the length of the parallel portions of the two adjacent ablated lines, are performed and then the arithmetic medium is calculated.

For example, if the length of the parallel portion of the two adjacent ablated lines is 80 millimetres respectively, the gap is measured at both ends and at three further points distanced 20 millimetres, forty millimetres and sixty millimetres respectively from one end of the parallel portion, preferably from the lower end of the ablated line.

The first edge portion may comprise any suitable number of ablation lines. For example, in some preferred embodiments the first edge portion comprises five or less ablated lines at any given longitudinal position on its inner surface. If more than five ablated lines are provided at any given longitudinal position on the first edge portion, it can become difficult to measure the angle (α) for each ablation line.

The ablated lines may have any suitable extension profile in the longitudinal direction of the first edge portion. For example, an ablated line may follow a curved trajectory over at least a portion of its extension profile in the longitudinal direction of the first edge portion. In such embodiments, the facet created by such an ablated line will have a non-linear perimeter.

In some preferred embodiments, the one or more ablated lines comprise at least two ablated lines that extend in parallel over at least a part of the first edge portion in its longitudinal direction. This can produce a substantially rectangular shaped facet at the first edge portion. In some particularly preferred embodiments, all of the one or more ablated lines in the first edge portion extend in parallel along the longitudinal direction of the first edge portion. This can produce a first edge portion having only substantially rectangular shaped facets.

The blank is preferably a cellulose-fiber-based laminar blank. Preferably, the laminar blank is formed from cardboard or paperboard.

The terms “cellulose-fiber-based laminar blank” is used herein to refer to a laminar blank comprising at least 50 percent by weight of cellulose fibers, based on the total fiber content of the laminar blank. The cellulose-fiber-based or wood-fiber-based laminar blank of the invention may include other types of fibers, such as polymer fibers.

Preferably, the laminar blank has a basis weight of between about 100 grams per square metre and about 350 grams per square metre. In some preferred embodiments, the laminar blank has a basis weight of from about 160 grams per square metre to about 240 grams per square metre. It is understood, that these ranges represent average values and that the basis weight of the laminar blank may vary between several batches, e.g. plus ten percent or minus ten percent, preferably plus 5 percent or minus five percent. For obtaining a bevelled edge portion, preferably, the preferred basis weight range is combined with an average distance between two adjacent ablation lines measured from their inner adjacent edges of from about 1.2 mm to about 6 mm, more preferably from about 1.2 mm to about 4 mm.

Preferably, the thickness (T) of the laminar blank is from about 260 micrometres to about 360 micrometres. More preferably, the thickness (T) of the laminar blank is from about 300 micrometres to about 350 micrometres. The thickness (T) of the laminar blank can be measured in accordance with ISO 534:2011.

Preferably, the ablated width (X) of each ablation line is at least about 0.2 millimetres. More preferably, the ablated width of each ablation lines is at least about 0.3 millimetres. In addition, or as an alternative, the ablated width of each ablation lines is less than about 0.5 millimetres. More preferably, the ablated width of each ablation lines is less than about 0.45 millimetres. In some preferred embodiments, the ablated width of each ablation lines is from about 0.1 millimetres to about 0.5 millimetres. Even more preferably, the ablated width of each ablation line is from about 0.2 millimetres to 0.45 millimetres, more preferably from about 0.3 millimetres to 0.4 millimetres.

Preferably, the first planar wall is orthogonal to the second planar wall.

Preferably, the container has a spring-back force of less than about 10 milliNewton metres between the two planar walls that are connected by the first edge portion.

In some preferred embodiments, the laminar blank forms at least a part of the container comprising a box portion having a box front wall, a box rear wall and box side walls extending between the box front wall and the box rear wall, and wherein the first edge portion connects one of the box side walls to the box front wall or the box rear wall. Alternatively or additionally, the first edge portion may connect a box bottom wall with one of the box side walls, box front wall or the box rear wall.

In addition, or in alternative embodiments, the laminar blank preferably forms at least a part of the container comprising a lid portion having a lid front wall, a lid rear wall and lid side walls extending between the lid front wall and the lid rear wall, and wherein the first edge portion connects one of the lid side walls to the lid front wall or the lid rear wall. Alternatively or additionally, the first edge portion may connect a lid top wall with one of the lid side walls, lid front wall or the lid rear wall.

In some particularly preferred embodiments, the container comprises two or more edge portions along its transverse edges, longitudinal edges, or both, with each of said edge portions having any of the preferred features described above.

Containers according to the present invention find application as containers for consumer goods, in particular elongate consumer goods such as smoking articles. However, they can also be used for several other types of consumer goods, such as confectionary.

Preferably, the width (W) of the ablation area is at least about 2 millimetres. More preferably, the width of the ablation area is at least about 4 millimetres. In addition, or as an alternative, the width of the ablation area is preferably less than about 8 millimetres. More preferably, the width of the ablation area is less than about 6 millimetres.

Preferably, the distance (Y) between adjacent ablation lines in the ablation area is at least about 1.2 millimetres. More preferably, the distance (Y) between adjacent ablation lines in the ablation area is at least about 1.5 millimetres. In addition, or as an alternative, the distance (Y) between adjacent ablation lines in the ablation area is less than about 10 millimetres, more preferably less than about 6 millimetres. The distance (Y) should be measured between the two adjacent edges of the two adjacent ablation lines.

Preferably, the laminar blank has a stiffness in the bending direction of at least about 50 milliNewtons, preferably at least about 75 milliNewtons, most preferably at least about 90 milliNewtons, In addition, or in the alternative, the laminar blank has a bending stiffness of less than about 500 milliNewtons, preferably less than about 200 milliNewtons, more preferably less than about 160 milliNewtons. The laminar blank preferably has a bending stiffness from about 50 milliNewtons to about 200 milliNewtons. More preferably, the laminar blank has a stiffness in the machine direction of from about 75 milliNewtons to about 160 milliNewtons. Stiffness in the “bending direction” means that the bending stiffness is measured in the direction that the finished board is intended to be folded about the ablation zone.

Preferably, the laminar blank has a stiffness in the bending direction of at least 10, preferably at least 12, more preferably at least 15 and even more preferably at least 20 milliNewtons. More preferably, the laminar blank has a residual stiffness in the bending direction of from about 60 or less, preferably, 50 or less, even more preferably 40 or less milliNewtons.

Preferably, the laminar blank has a surface roughness of from about 0.5 micrometres to about 1.5 micrometres. More preferably, the laminar blank has a surface roughness of from about 0.75 micrometres to about 1.25 micrometres. The surface roughness may be measured in accordance with ISO 8791-4.

Preferably, the laminar blank has a surface strength of from about 1 metres per second to about 2 metre per second. More preferably, the laminar blank has a surface strength of from about 1.25 metres per second to about 1.75 metres per second. The surface roughness may be measured in accordance with ISO 3783.

The container may optionally comprise an outer wrapper, which is preferably a transparent polymeric film of, for example, high or low density polyethylene, polypropylene, oriented polypropylene, polyvinylidene chloride, cellulose film, or combinations thereof and the outer wrapper is applied in a conventional manner. The outer wrapper may include a tear tape. In addition, the outer wrapper may be printed with images, consumer information or other data.

Further, the consumer articles may be provided within the container in the form of a bundle wrapped in an inner package formed of metal foil or metallised paper. The inner package material may be formed as a laminate of a metallised polyethylene film, and a liner material. The liner material may be a super-calendered glassine paper. In addition, the inner package material may be provided with a print-receptive top coating. The inner package has an access opening through which consumer goods can be removed when a lid of the container is in a respective open position.

The container is preferably a rectangular parallelepiped comprising two wider walls spaced apart by two narrower walls. Hinge lid containers according to the invention may be in the shape of a rectangular parallelepiped, with longitudinal and transverse edges. In such embodiments, one of the longitudinal or transverse edges corresponds to the first edge portion of the laminar blank. Each of said longitudinal or transverse edges may have any of the preferred features described above.

Preferably the first edge portion has a width of between about 2 mm and about 8 mm, preferably between about 4 and about 6 mm.

Containers according to the invention find particular application as packs for elongate smoking articles such as, for example, cigarettes, cigars or cigarillos. It will be appreciated that through appropriate choices of the dimensions thereof, containers according to the invention may be designed for different numbers of conventional size, king size, super-king size, slim or super-slim cigarettes. Alternatively, other consumer goods may be housed inside the container.

Through an appropriate choice of the dimensions, containers according to the invention may be designed to hold different total numbers of smoking articles, or different arrangements of smoking articles. For example, through an appropriate choice of the dimensions, containers according to the invention may be designed to hold a total of between ten and thirty smoking articles.

The smoking articles may be arranged in different collations, depending on the total number of smoking articles.

Containers according to the present invention may hold smoking articles of the same type or brand, or of different types or brands. In addition, both filter-less smoking articles and smoking articles with various filter tips may be contained, as well as smoking articles of differing length (for example, between about 40 mm and about 180 mm), diameter (for example, between about 4 mm and about 9 mm). Preferably, the dimensions of the container are adapted to the length of the smoking articles, and the collation of the smoking articles. Typically, the outer dimensions of the container are between about 0.5 mm to about 5 mm larger than the dimensions of the bundle or bundles of smoking articles housed inside the container.

The length, width and depth of containers according to the invention may be such that the resultant overall dimensions of the container are similar to the dimensions of a typical disposable pack of twenty cigarettes.

Preferably, containers according to the invention have a height of between about 60 mm and about 150 mm, more preferably a height of between about 70 mm and about 125 mm, wherein the height is measured from the bottom wall to the top wall of the container.

Preferably, containers according to the invention have a width of between about 12 mm and about 150 mm, more preferably a width of between about 70 mm and about 125 mm, wherein the width is measured from one side wall to the other side wall of the container.

Preferably, containers according to the invention have a depth of between about 6 mm and about 150 mm, more preferably a depth of between about 12 mm and about 25 mm wherein the depth is measured from the front wall to the back wall of the container.

Preferably, the ratio of the height of the container to the depth of the container is in between about 0.3 to 1 and about 10 to 1, more preferably between about 2 to 1 and about 8 to 1, most preferably between about 3 to 1 and 5 to 1

Preferably, the ratio of the width of the container to the depth of the container is in between about 0.3 to 1 and about 10 to 1, more preferably between about 2 to 1 and about 8 to 1, most preferably between about 2 to 1 and 3 to 1.

Preferably, the ratio of the height of the lid back wall to the height of the box back wall of the outer sleeve is between about 0 to 1 (lid located at the top edge of the container) to about 1 to 1, more preferably, between about 1 to 5 and about 1 to 10, most preferably, between about 1 to 6 to about 1 to 8.

Preferably, the ratio of the height of the lid front wall of the outer sleeve to the height of the box front wall of the outer sleeve is between about 1 to 0 (lid covering the entire front wall) to about 1 to 10, more preferably, between about 1 to 1 and about 1 to 5, most preferably, between about 1 to 2 and about 1 to 3.

The exterior surfaces of containers according to the invention may be printed, embossed, debossed or otherwise embellished with manufacturer or brand logos, trade marks, slogans and other consumer information and indicia.

Containers according to the invention may be filled and assembled using conventional apparatus and methods, modified to include the step of forming two or more ablated lines in the blank. The ablated lines may be produced using an ablation tool, such as a laser or a blade. A laser is particularly preferred as the ablation tool as it can allow for a wide variety of ablation profiles and configurations, with minimal adjustment of the laser tool being needed. For example, the laser may be repeatedly passed over a given portion of the blank to iteratively remove different amounts of material, allowing for a very finely controlled ablation profile. It is also beneficial if fine ablated lines are required, with narrow widths. It is possible to accurately control the relative movement of the laser and the blank so as to form any type of pattern with varying removal intensity (“depth”) over the ablation area.

The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 depicts a perspective view of a container having at least one edge portion according to an embodiment of the present invention;

FIG. 2 depicts a cross-sectional view of a portion of the laminar blank for forming the container of FIG. 1, shown in an unfolded condition;

FIG. 3 depicts a cross-sectional view of a portion of the laminar blank for forming the container of FIG. 1, shown in a folded condition;

As can be appreciated by the skilled person, FIG. 1 shows a container 100 for consumer goods, which can be formed by folding a cardboard or paperboard laminar blank having a thickness (T).

The container 100 is a substantially rectangular parallelepiped in shape and comprises a box portion 30 and a hinge lid 40 connected to the box portion 30 along a hinge line 50 extending across the back wall of the container 100. The overall size and construction of the box 30 and lid 40 of the container 100 is substantially the same as those of a standard hinge lid cigarette pack. The box portion 30 comprises a box front wall, a box back wall, a box bottom wall, a box left side wall and a box right side wall. The hinge lid 40 comprises a lid front wall, a lid back wall, a lid top wall, a lid left side wall and a lid left side wall. The hinge lid 40 is pivotable about the hinge line 50 between a closed position and an open position. In the closed position, the hinge lid 40 cover an access opening of the container 100 and the walls of the hinge lid 40 form extensions of the corresponding walls of the box portion 30. In the open position, the hinge lid 40 pivots about the hinge line 50 to project backwardly from the box portion 30 and the access opening at the top end of the box portion 30 be fully uncovered. The box portion 30 and the hinge lid 40 may be formed together from a single laminar blank having a thickness T. The container may be assembled from the laminar blank and filled using standard apparatus.

The container comprises a first planar wall 4, which in FIG. 1 is a side wall of the box portion 30. The container also comprises a second planar wall 8, which in FIG. 1 is the front wall of the box portion 30. The side wall 4 and the front wall 8 are connected to each other by a first edge portion 20, which is shown in FIG. 1 as a bevelled edge portion 20. Although not visible from the perspective view in FIG. 1, the inner surface of the bevelled edge portion 20 comprises first and second ablation lines that each define respective turning points 22 and 24 of the bevelled edge portion, when the container 100 is assembled. The turning points 22 and 24 extend in parallel with one another in the longitudinal direction of the bevelled edge portion 20, to thereby define a single rectangular facet 6 of the bevelled edge portion 20.

The laminar blank therefore transitions from the side wall 4 to the facet 6 by an angle (22α) about the first ablation line defining turning point 22. The first ablation line should therefore be designed to have a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, such that the angle (22α) is within five degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

Similarly, the laminar blank transitions from the facet 6 to the front wall 8 by an angle (24α) about the second ablation line defining turning point 24. The second ablation line should therefore be designed to have a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, such that the angle (24α) is within five degrees of:

$2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$

This can be best appreciated from FIGS. 2 and 3 which show cross sectional views of the first edge portion 20 in an unfolded and folded condition respectively. In particular, FIG. 2 shows the laminar blank in an unfolded substantially flat condition, with the first ablation line 220 and the second ablation line 240 being substantially V-shaped in their cross-sectional profile. FIG. 3 shows the blank in a folded condition, whereby the side walls of each ablation groove's 240, 220 sidewalls have been brought together to abut one another. The blank has been folded such that an angle 24α exists between the outer surface of the front wall 8 and the facet 6, and an angle 22α exists between the outer surface of the side wall 4 and the facet 6. As a consequence of the ablation line designs, and fold angles 24α and 22α, the bevelled edge portion 20 can have an improved strength and be less vulnerable to local deformation.

FIGS. 2 and 3 are provided purely for illustrative purposes, and it will be appreciated that are they are not necessarily schematically accurate or to scale. 

1. A container for consumer articles, the container being at least partially formed from a laminar blank having an inner surface and an outer surface, and a thickness (T) of from about 100 micrometres to about 350 micrometres, the laminar blank defining a portion of the container that comprises: a first planar wall; and a second planar wall connected to the first planar wall by a first edge portion, wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, wherein the laminar blank is folded about the one or more ablated lines of the first edge portion such that, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of: $2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$
 2. A container according to claim 1, wherein the angle (α) is at least: $2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$
 3. A container according to claim 1, wherein each of the one or more ablated lines is formed as a substantially V-shaped groove within the blank.
 4. A container according to claim 1, wherein each of the one or more ablated lines has a minimum residual thickness (RT) of at least about 20 percent of the thickness (T) of the laminar blank.
 5. A container according to claim 1, wherein the first edge portion comprises five or less of said ablated lines at any given longitudinal position on its inner surface.
 6. A container according to claim 1, wherein the one or more ablated lines extend in parallel in the longitudinal direction of the first edge portion.
 7. A container according to claim 1, wherein the laminar blank is a cellulose-fiber-based or wood-fiber-based laminar blank.
 8. A container according to claim 1, wherein the ablated width of each of the one or more ablated lines is between about 0.1 millimetres and about 0.5 millimetres.
 9. A container according to claim 1, wherein the first planar wall is orthogonal to the second planar wall.
 10. A container according to claim 1 comprising: a box portion comprising a box portion front wall, a box portion back wall, first and second box portion side walls, and a box portion bottom wall; and a lid portion depending along a hinge line from a top edge of the box portion, wherein the lid portion is moveable about the hinge line between an open position and a closed position.
 11. A container according to claim 11, wherein the first planar wall is the box portion front wall, and the second planar wall is the first box portion side walls.
 12. A laminar blank for forming a container for consumer articles, the laminar blank having an inner surface and an outer surface, and a thickness (T) of from about 100 micrometres to about 350 micrometres, the blank comprising: a first wall panel for forming a first planar wall of the container; and a second wall panel for forming a second planar wall of the container, the second wall panel being connected to the first wall panel by a first edge portion; and wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion, and wherein the laminar blank is configured to be folded about the one or more ablated lines of the first edge portion such that when folded, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of: $2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$
 13. A method of forming a container for consumer articles, the container being at least partially formed from a blank having a thickness (T) of from about 100 micrometres to about 350 micrometres, the method comprising: providing a laminar blank having a thickness (T), the blank comprising: a first wall panel for forming a first planar wall of the container; and a second wall panel for forming a second planar wall of the container, the second wall panel being connected to the first wall panel by a first edge portion; wherein the inner surface of the first edge portion comprises one or more ablated lines extending substantially in the longitudinal direction of the first edge portion, wherein each of the one or more ablated lines is provided as a groove within the blank, having a minimum residual thickness (RT) of from about 15 percent to about 40 percent of the thickness (T) of the laminar blank, and an ablated width (X) as measured transversely to the longitudinal direction of the first edge portion; and folding the first wall panel of the laminar blank relative to the second wall panel, such that, for each ablated line, the angle (α) between the outer surface of a first planar portion of the blank adjacent to one side of the ablated line and the outer surface of second planar portion of the blank adjacent to the other side of said ablated line, is within 5 degrees of: $2{\tan^{- 1}\left( \frac{X}{2\left( {T - {RT}} \right)} \right)}$ 